RWE Power International

ENGINEERING & CONSULTING SERVICES DRIVEN BY RWE’S OPERATIONAL AND NEW BUILD EXPERIENCE

2 RWE POWER INTERNATIONAL – RE GMBH

ABOUT US 3

RWE POWER INTERNATIONAL – RE GMBH • is RWE’s engineering consulting company. Our highly specialised expertise and outstanding performance stem from our employees’ experience as part of one of the world’s largest energy and mining groups. • offers external clients tried and trusted procedures and innovative solutions that have proven to be effective within RWE for widely diversified projects

employing the latest construction methods. As an owner and operator, we are independent of suppliers and equipment manufacturers.

Our worldwide project locations

• represents the skill set of the RWE Group. • RE GmbH, formerly RHEINBRAUN ENGINEERING, was founded in 1965.

Mining Power Generation

Our services • Our services cover all aspects of the power generation business. This includes everything from feasibility through to planning, construction as well as commissioning, operation, maintenance and – if needed – decommissioning. • Our in-depth knowledge of mining incorporates diverse types of ore and coal, and ranges from feasibility and mine development to operation, maintenance and recultivation. • With over 50 years of experience in large-scale mining projects, we are in the ideal position to provide unrivalled support to our clients for the construction and optimisation of conveyor systems.

Our team • RWE Power International’s success is built on the capabilities of our talented specialists in a variety of disciplines: project managers, quality managers, engineers, procurement and claim experts, designers, planners, geologists, environmental scientists and economists. Numerous other specialists from associated disciplines contribute to our team’s strength. • Our clients around the world benefit from our independent engineering expertise. Our experts have many years of invaluable practical insights acquired through the operation of our own power plant and mining sites.

4 RWE – POWER GENERATION

GENERATION BACKGROUND 5

50 GW INSTALLED CAPACITY. 18,000 EMPLOYEES. 70+ LOCATIONS. OUR POWER GENERATION KNOWLEDGE BASE

RWE operates • the most diversified generation mix in Europe: lignite, hard coal, biomass, gas, hydro and nuclear. • one of Europe’s largest and most efficient gas fired power plants (CCGT): Pembroke Power Station produces over 2,000 MW at 58% efficiency. • the world’s most efficient super critical lignite fired power plants: BoA 2&3. Each unit has a capacity of 1,100 MW and 42% efficiency rating. • the first industrial size continuous lignite drying plant: fluidised-bed drying with internal waste heat utilisation, wet coal ~210 t/h, dry coal ~110 t/h. • the most modern hard coal power plant which can be partially fuelled by biomass: Eemshaven Power Station will produce 1,600 MW at 46% efficiency.

BoA 2&3 Neurath

Staythorpe

Start-up: 2012 Fuel: lignite Capacity: 2,200 MW

Start-up: 2011 Fuel: natural gas Capacity: 1,700 MW

Pembroke Start-up: 2012 Fuel: natural gas Capacity: 2,188 MW

Westfalen W e Unit U n D/E Star Start-up: Sta a 2013 FFuel: Fue ue hard coal Capacity: 1,528 MW Cap

Lingen Start-up: 2010 Fuel: natural gas Capacity: 887 MW

Denizli Start-up: 2013 Fuel: natural gas Capacity: 775 MW

Claus C Start-up: 2012 Fuel: natural gas Capacity: 1,304 MW

Moerdijk 2 Mo Start-up: 2012 Sta Fuel: natural gas Fue Capacity: 426 MW Ca

Eemshaven Ee Start-up: 2014 St Sta Fuel: hard coal/biomass Fu Capacity: 1,560 MW Ca

By 2014 RWE will have renewed 25% of its generation fleet.

6 POWER GENERATION SERVICES

POWER GENERATION SERVICES 7

EXPERIENCED. FOCUSSED. FLEXIBLE. Achieve sustainable improvement in plant performance with the support of RWE Power International’s cutting-edge services. Project Development and Management From preliminary study to investment decision • Site evaluation • Estimation of capital expenditure (Capex) • Concept, pre-feasibility and feasibility studies • Project scheduling and cost estimations • Technical due diligence • Support of studies for licensing and permits • Development of contract/procurement strategy • Supplier evaluations • Project planning, controlling and monitoring

Engineering Support • Technical contract management • Design management • Technical specifications and definition of requirements • Review of basic/detailed engineering • Interface management for technical lots • Technical consultancy in specialist areas • Plant operation optimisation and operational support • Retrofit and lifetime extensions

Health and Safety, Quality, Environment Project and technical services: • Expediting and on-site surveillance • Quality control and inspections • Expert witness, materials testing and damage analysis • Consulting on materials and technical components Management system services: • Quality management system development • Environmental management system development • Supplier quality evaluation and auditing Documentation services: • Document management • Technical data management Nuclear Industry • Technical analysis of nuclear new build projects • Operational safety assessment of Nuclear Power Plants (NPP’s) • Efficiency enhancement of NPP’s • Maintenance measures and outage performance management • Transfer of management know-how and safety culture • Training tailored to local requirements

Maintenance Services and Ash Products TSG Ferrybridge • Maintenance, overhaul and modification • Outage management • Support for plant refurbishment, repair and upgrade • Inspections • Manufacturing of spare parts • Steam and gas turbine specialist services Generation Aggregates • Provision of cost effective, readily available ash products for construction and engineering applications • Monitoring of ash quality in accordance with the Quality Protocol to ensure its suitability • Advice on the standards relevant to the use of ash • Provision of technical data to enable you to assess the suitability of ash in your particular application • Advice on best practices for use in your application

PLANNING, CONTROLLING AND DELIVERING

HANDOVER

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INITIAL IDEA

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QUALITY

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CONSTRUCTION

PROJECT ENGINEERING

8 POWER GENERATION PROJECT EXPERIENCE

POWER GENERATION PROJECT EXPERIENCE 9

KNOWLEDGEABLE. WELL-ROUNDED. PROVEN. When it comes to the construction of modern power plants, there are few energy businesses that have as much international experience as RWE Power International.

From conventional electricity generation to regenerative technologies, from large-scale power plants to smaller, decentralised systems: our engineers have a wealth of experience as owners and operators of the most diverse types of power plants.

RWE Power International possesses worldwide experience in the modernisation and replanting of all types of power stations.

We make use of our in-depth knowledge to secure the long-term value of our clients’ assets. Our engineers help our clients to extend the life of their power plants and make lasting improvements to plant performance.

A good example of RWE Power International’s newbuild projects is the BoA 2&3 project in Neurath, Germany. There, we have constructed the world’s most modern and most efficient lignite-fired power plant to replace older, less efficient plants. We like to think big. Take our combined cycle power plant at Pembroke in the UK which is the largest of its type in Europe.

NEW BUILD

In addition to Pembroke and Staythorpe in the UK we have also just completed some of the most technically advanced new combined cycle power plants in Germany, the Netherlands and Turkey. Our experts have also just built dedicated biomass projects in Scotland, Germany and Italy. Always on the cutting edge of technology, we are nearing completion of a 1,600 MW hard coal power plant in Hamm, Germany and Eemshaven in the Netherlands. Through targeted process optimisation, the power plant is to achieve an efficiency of up to 46%.

New turbines for CCGT Little Barford, UK

Boiler structural steelwork for the hard coal power plant Hamm, Germany

Numerous power plants around the world serve as examples of how successful we are at modernising and refurbishing existing plants. For example, in Hungary and South Africa, we succeeded in increasing the output of several power plants whilst also significantly extending their operational life and ensuring full compliance with environmental requirements.

REPL ANTING

In south eastern Europe, we supported several boiler system modernisation projects. In the first stage of these projects, we provided the technical specifications with particular focus on increasing efficiency and reducing NOx emissions. Subsequently we assisted with the evaluation of bids for tender. During the refurbishment stage we advised the owner regarding the ongoing works on-site and in technical discussions with suppliers.

10 POWER GENERATION PROJECT EXPERIENCE

QUALITY AND VENDOR CERTIFICATIONS 11

QUALITY. HEALTH AND SAFETY. ENVIRONMENT. With experience in a variety of modernisation measures and safety upgrades, our engineers can be relied on for professional consulting and proven project management for nuclear power plants.

For more than ten years, our nuclear experts have been helping to improve the safety of nuclear power plant projects around the world. Whether they are shift leaders, trainers or project managers, the members of our nuclear team all have specific expertise in certain aspects of nuclear power plant construction and operation. Equipped with this in-depth knowledge, we support several international missions as well as several EU expert committees on nuclear safety. Our nuclear fleet comprises four units in operation, with a total capacity of 4,400 MW and five units in the decommissioning phase.

Our services are quality approved: IS0 9001 accredited IS0 14001 accredited OSHAS 18001 accredited

NUCL E A R

We provide consultancy services in the nuclear field to public institutions as well as to private companies. We possess in-depth knowledge regarding Generation I to Generation III reactors as well as the

View into cooling basin of Biblis Power Plant, Germany

View from the technical training center of NPP Zaporozhye, Ukraine

commissioning and decommissioning of all types of nuclear power plants. We have contributed our expertise to nuclear development programmes in Belene, Bulgaria; Cernavoda, Romania and the Horizon project in the United Kingdom. We offer detailed knowledge of technical design standards and international licensing standards. In the field of nuclear power, our tasks typically include the assessment of technical requirements, preparation of technical specifications, contracting and onsite management during every stage of a project. We are also ideally placed to assist you with measures for radiation protection and radioactive waste management.

We are an Achilles recognised company. regic

RePro

Registrado

Registrado

No regic: 504017

No RePro: 342106

apu sms

Accredited

No apu sms: 006184

12 RWE – LIGNITE MINING

RWE operates • three totally continuous open pit mines, producing 100 Mt/a lignite. • 20 of the world’s largest bucket wheel excavators (up to 240,000 m³/d). • 18 inpit overburden spreaders, to dump more than 480 M bcm/a. • 240 km of up to 2.8 m wide belt conveyors, running at 7.5 m/s. • the largest private European heavy duty rail network with a length of 565 km for coal transport. • 19 km/a exploration and 45 km/a dewatering drilling.

Garzweiler Mine 35 – 40 Mt/a

Tagebau Garzweiler

Hard coal

Hambach Mine 35 – 40 Mt/a

Lignite with integrated opencast mines

Bremen



Natural gas Nuclear power stations

Rh ine

Inden Mine 20 – 25 Mt/a

Dortmund Cologne

Cologne Aachen Frechen

*

Tagebau Inden B

Production capacity: ~100 Mt/a

7 47

Other conventional power plants Hydropower stations** * in deconstruction ** RWE Power including holdings as well as plants operated on behalf of RWE Innogy

Tagebau Hambach

Frankfurt

L 238 n

HAMBACH MINE. GARZWEILER MINE. INDEN MINE. OUR MINING KNOWLEDGE BASE

MINING BACKGROUND 13

Mainz

n

Berrenrath KW Knapsacker Hügel

Saarbrücken

Dürwiß

Stuttgart

Reserves, legally secured: 3.3 billion t

Munich as of 01/2013

14 MINING SERVICES

MINING SERVICES 15

INNOVATIVE. SUCCESSFUL. SOPHISTICATED. We are committed to maximising value from your mining assets by tailoring our Services to your needs.

Our Specialists • plan and develop your mines towards truly continuous mining operations. • assist with the establishment of state-of-the-art mining technology and techniques, e.g. IPCC. • provide the necessary transfer of skills to your own operators.

• ensure minimal impact on the surrounding environment throughout the mine’s life. • support you throughout your total mining process.

Mine Design, Planning and Optimisation • Conceptual and detailed mine design studies • Individual opencast mine planning such as IPCC • Net-present-value pit optimisation • Choice of mining method and haulage method • Life-of-mine stockpile, waste dump and tailings dam design • Production and equipment schedule optimisation • Run-of-mine tonnage and grade scheduling • Equipment, staff and material requirements determination

In-pit Crushing and Conveying (IPCC) • Conceptual and detailed IPCC mine design • Brownfield integration planning • Equipment selection advice

Geological Services • Exploration management • Hydrological assessment • Acid mine drainage studies • Geotechnical assessment

Conveying Engineering • Design of the whole conveyor chain-systems • Independent checking and verification of an equipment manufacturer’s design • Preparation of tender documents • Evaluation of bids and recommendation of the most suitable bidder • Assistance during contract negotiations • Mine equipment erection supervision

Equipment Maintenance and Optimisation • Development of a suitable maintenance strategy • Maintenance planning and organisation • Mine maintenance and warehouse management • Maintenance training, audits and benchmarking • Mine maintenance development • Check and verification of the mine equipment’s rehabilitation needs

Conveyor Belt Inspection • Direct feedback of recommended improvements at plant inspection • Analysis of plant breakdown • Proposals for plant improvement through detailed analysis

Conveyor Belt Testing (laboratory) • Conveyor belt testing according to DIN, ISO and other international standards (all testing equipment available) • Belt testing according to RWE standards for heavy duty mining demand (large scale testing) • Expertise in belt failure analysis and lifetime prediction

16 MINING PROJECT EXPERIENCE

MINING PROJECT EXPERIENCE 17

RELIABLE. VISIONARY. DURABLE. In opencast mining, the use of In-Pit Crushing and Conveying (IPCC) systems is becoming increasingly common.

There are good reasons for this. As far as fuel consumption, carbon dioxide emissions and time are concerned, modern IPCC systems have clearly proven to be more efficient than traditional “shoveland-truck” methods. With mounting international pressure on mining companies to increase their environmental responsibility, the new technology is becoming more and more attractive – not to mention the potential savings on fuel and operating costs.

Truck dumping into hopper of semi-mobile crusher plant at Maeh Moh Mine, Thailand

The overall expenses for haulage systems that still rely on shovel-and-truck can easily add up to 50% of the total mining costs. Although the initial expenditure that is generally needed for an IPCC system can be significant, it soon pays back due to a high return on investment.

An IPCC system consists of a crusher that is connected to several conveyors. The crusher is strategically positioned in the opencast mine and the conveyors remove the crushed material. A major advantage of this system is that while trucks are only able to transport overburden, ore or coal on inclines up to 12%, the conveyors can operate safely and reliably at gradients of up to 25%. Therefore, this not only reduces the distance that the material has to travel from the pit but it also lowers costs for fuel, maintenance and personnel.

Of our many support services, none is more in demand than our mining equipment engineering support.

Our experience in this area is wide-ranging, both geographically and technically. Whatever your project – coal, copper, ore or overburden – RWE Power International is your best choice for the task. For example, we built the world’s largest compact bucket wheel excavator for the Bükkábrány opencast mine in Hungary. Our engineers were responsible for drafting the plans, constructing the coal storage and selecting and qualifying the suppliers.

IPCC

We have many years of experience using IPCC, particularly in South America. Our first project was in Chile in the early 1990s with the design, development and supervision of the construction of a crusher-belt conveyor-spreader system. After successfully completing this project, our team was subsequently awarded a contract by the Chilean copper mining company Codelco. In 1995, we were awarded a contract to construct a tunnel conveyor to transport ore 1,200 metres downhill from Antofagasta’s Los Pelambres copper mine. We continue to assist the company with the operation and maintenance of the system. In addition, we have conducted numerous IPCC studies for locations around the world, including Peru, Columbia, Thailand, India, Indonesia and Australia.

project from the start through to completion, therefore ensuring that the production quality remained consistently high throughout and maintaining the same high standard for which our mining projects are known. In Serbia, we conducted similar projects for the state electricity company, EPS including supporting the completion of complex overburden removal systems. We also analysed existing bulk ore conveyor and transport systems for several copper mines in Chile to identify weak points. We then developed a number of solutions for improving performance and increasing throughput.

World largest compact bucket wheel excavator in Bükkábrány Opencast Mine, Hungary

The parts for the excavator were manufactured in several European countries including Bulgaria and Poland. Before the first elements were manufactured, we conducted construction audits and during the production stage we held factory acceptance tests for key components. Our experts guided and supervised the

Our customers can be confident of maximum safety and reliability when they purchase conveyor belts which are “RWE tested”. We want you to feel confident that you integrate reliable components into your production system. For this reason, we refuse to buy any products that have not successfully withstood rigorous testing in our own laboratories.

EQUIPMENT ENGINEERING

18 MINING PROJECT EXPERIENCE

HOW TO REACH US 19

HELPFUL. INTERCONTINENTAL. ACCESSIBLE. Mining

Power Plant

Stuettgenweg 2 50935 Cologne Germany T +49 221 480 1300 F +49 221 480 1350

Huyssenallee 2 45128 Essen Germany T +49 201 12 22673 F +49 201 12 22671

Building on many years of specialised expertise, we provide our clients with one-stop solutions covering the entire cycle of a mining project.

Our practical experience covers all types of opencast mining and construction projects. For instance as part of a mine feasibility study, we conducted exploration drilling and hydrological pump tests in the Thar Desert in Pakistan. The investigations revealed lignite reserves of around 400 million tonnes. For an opencast mining project in the Bushveld Complex in South Africa, our experts drafted a precise model of a platinum-palladium deposit which enabled the client to carry out highly targeted mining operations. On a contract for Neyveli Lignite Corporation (NLC), which operates several opencast lignite mines in southeast India, we conducted a feasibility study including detailed mine planning. Our experts needed to overcome a number of geotechnical, environmental and technological challenges. For the duration of the project, we supported NLC on site and also via internet from Cologne.

MINE PL ANNING

Our mining engineering team in the clients office in Indonesia

Further information may be found on our website: www.rwepi.com

The Gallilee Coal Basin in Australia is being developed by several mining companies. Our team of experts is involved in concept and feasibility stage studies, especially when it comes to the utilisation of continuous mining equipment. To develop totally continuous operating coal and overburden transport systems our operational knowledge is of extraordinary value in the fields of mine stage planning and equipment selection.

Maintenance Services and Ash Products TSG Ferrybridge – Maintenance Services Old Great North Road / Knottingley West Yorkshire / WF11 8PR United Kingdom T +44 1977 632201 F +44 1977 632311

Meet us at selected fairs, exhibitions and conferences.

Generation Aggregates Electron / Windmill Hill Business Park Whitehill Way / Swindon Wiltshire / SN5 6PB United Kingdom T +44 800 7312865 F +44 1793 892421

RWE Power International RE GmbH Stuettgenweg 2 50935 Cologne T +49 221 480 1300 F +49 221 480 1350 I www.rwepi.com E [email protected] Huyssenallee 2 45128 Essen Germany T +49 201 12 22673 F +49 201 12 22671 Registered Office: Registered at Cologne Local Court under no. HRB 2635 © 3/2013 RE GmbH